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Quality Management System Guidelines Version 1.0 – 15 July 2014
Quality Management System
Guidelines
Version 1.0 – 15 July 2014
Quality Management System Guidelines Version 1.0 – 15 July 2014
Quality Management System Guidelines Version 1.0 – 15 July 2014

Title:

NB QMS Guidelines

Version:

15 July 2014

Filename:

QMS Guidelines_V1.0_7.2014 ppt

Document owner:

Mark Woodworth Manager Regional Quality Control, Asia

Distribution:

NB Factory Quality Teams/LO’s in Asia

Contents

  • 1. Introduction

1.1.

Background

1.2.

Purpose

1.3.

QMS Organization Structure

1.4.

Recruitment and Training QMS personnel

  • 2. QMS Guidelines

    • 2.1 Incoming Materials Warehouse and Inspection

    • 2.2 Implementation On the Line

    • 2.3 Finish Goods Warehouse

1.1 Background

1. Introduction

The New Balance Quality Management System (QMS) detailed in these Guidelines are recommended actions for monitoring and controlling quality from Incoming Materials through the production process to the Finished Goods Warehouse and Shipping Inspections.

These Guidelines will be focused on achieving New Balance quality policies and objectives to ensure we are meeting our customers wants and needs and will be expressed as the organizational structure, policies,

procedures, processes and resources needed to implement effective

quality management.

1.2 Purpose

The purpose of the NB QMS Guidelines is to provide our T1 factories a clear, but flexible set of requirements to control footwear product quality end-to-end and provide the basis for periodic audit by NB, as well as to create mutual trust and greater synergy with our factory partners.

1. Introduction

1.3 QMS Organization Structure

NB T1 factories must prepare a QMS organization chart in the format shown below.

QMS Manager QMS Procedure QMS Supervisor QMS Supervisor QMS Supervisor RQC EOLQC RQC EOLQC RQC EOLQC
QMS Manager
QMS Procedure
QMS Supervisor
QMS Supervisor
QMS Supervisor
RQC
EOLQC
RQC
EOLQC
RQC
EOLQC

1. Introduction

1.4 Recruitment & Training QMS Personnel

For the recruiting and training of QMS Personnel such as EOL Inspectors, Roving QC Inspectors & SI Inspectors from both inside and outside the factory (see attachment).

1. Introduction 1.4 Recruitment & Training QMS Personnel For the recruiting and training of QMS Personnel

2. QMS Guidelines Scope

  • 2.1 Incoming Materials W/H & Inspection

  • 2.2 Implementation on the Line

(Quality Control in Production)

  • 2.3 Finished Goods Warehouse

2.1 Incoming Materials Warehouse & Inspection
2.1
Incoming Materials
Warehouse & Inspection

Incoming Material Warehouse Lay out

Incoming Reject C C Release Area Materials Area
Incoming
Reject
C
C
Release Area
Materials
Area
Incoming Material Warehouse Lay out Incoming Reject C C Release Area Materials Area Inspection Areas Incoming
  • Inspection Areas

Incoming Material Warehouse Lay out Incoming Reject C C Release Area Materials Area Inspection Areas Incoming
Incoming Material Warehouse Lay out Incoming Reject C C Release Area Materials Area Inspection Areas Incoming
Incoming Materials A A B B
Incoming
Materials
A
A
B
B

= Leather Inspection = Synthetic Inspection

= Accessories Inspection

Preparation Area Excess Release Area Material
Preparation
Area
Excess
Release Area
Material

As shown in the drawing, background color of area location ID signs should be same color as borders.

The lettering color on the area ID signs should be in contrast to the background color.

Incoming material Warehouse Color Coding

Material Storage Areas

Five colors are used to mark and identify location areas of material

storage according to material inspection status

Blue -

Incoming Inspection Area

  • Green- Released Area Preparation Area Excess Materials Area

Yellow -

Grey -

Red -

Rejected Area ( use Brown color for floor lines)

Color borders can be:

Painted: for permanent use

Taped: for temporary use

Width of borders = 60mm (recommended)

Incoming material Warehouse Color Coding Material Storage Areas Five colors are used to mark and identify
Incoming material Warehouse Color Coding Material Storage Areas Five colors are used to mark and identify
Incoming material Warehouse Color Coding Material Storage Areas Five colors are used to mark and identify
Incoming material Warehouse Color Coding Material Storage Areas Five colors are used to mark and identify
Incoming material Warehouse Color Coding Material Storage Areas Five colors are used to mark and identify

Flow Process Incoming Material

Fill out Tracking Unload material from truck or container N Pass Sticker with Failed Inspection result
Fill out Tracking
Unload material from
truck or container
N
Pass
Sticker with Failed
Inspection result
Y
Attach Red
Place material in
Inspection area
Physical test
‘Rejected’ sticker and
move to rejected area
Attach Tracking
Sticker and fill out
material information
N
Pass
Claim to T2 supplier
Y
Visual inspection
Fill out tracking
Sticker with passed
Inspection result
Attach Green
‘Released’ sticker and
move to release area

Incoming Material Tracking Stickers

This material tracking sticker must be placed on all incoming materials (1 per unit) for all incoming materials.

Stickers have White background with Black lettering.

Checker/QC Signature

PO. No.

Production Month

Quantity

Supplier Name

Packing

Dimensional Result

Visual result (Material)

Lab Test Result

to be checked prior release

Defect & grading check

Roll No/Lot/Batch

Date Received

Expire Date

Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
Material Name
Material Name
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
PASS FIFO FAIL
PASS
FIFO
FAIL
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab
Checker/QC Signature PO. No. Production Month Quantity Supplier Name Packing Dimensional Result Visual result (Material) Lab

FIFO (First it First out)

A FIFO sticker must be applied to all incoming materials.

  • For hardener, primer and adhesive chemicals:

the FIFO tracking month is the chemical’s production date.

  • For all other raw materials the FIFO month is the date the material arrives in the Incoming W/H

The background colors for the FIFO stickers are different month by month so 12 colors are used representing each month of the year. The month number is also printed on the sticker

An underline in added to number 6 and 9 to avoid confusion.

2
2

Diameter Ø 30 mm

  • 1

2
2
3
3
  • 4

5 6
5
6
  • 7

8 9
8
9
  • 10

11
11
12
12

13

Size & Location of Indication boards

The size of the area identification (ID) signs should be: A2

Placement of material location signs.

Area Location ID signs: Either hanging or place on walls indicating , Incoming Inspection area, Released area, Reject area, Preparation area or Excess Material area.

Storage row location signs: are placed at the top of the entrance to each row.

Storage Shelf Bins/Sections:

Each storage Row should be numbered 1,2,3,4, etc. Each shelve bins/section location should be identified by a letter e.g., A, B, C, D, At the entrance to each Row there should be a material location board which shows the row and bin/section location number and letter;

For example 2F = Row number 2, Bin/Section F.

With this system materials can be easily located.

Material location boards which show the Row and Bin/Section location number and letter

Material location boards which show the Row and Bin/Section location number and letter

Area Location ID Signs

Examples of area ID signs

Area Location ID Signs Examples of area ID signs Rejected area ( A2 size ) Released

Rejected area ( A2 size )

Area Location ID Signs Examples of area ID signs Rejected area ( A2 size ) Released

Released area ( A2 size )

Released area (A2 size)

Area Location ID Signs Examples of area ID signs Rejected area ( A2 size ) Released

PT. SINAR TIMUR INDUSTRINDO

REJECTED

 

PT. SINAR TIMUR INDUSTRINDO

RELEASED

Yes:

   

The sticker size is 95mm x 35mm

Example of Rejected sticker

(order with individual factory name)

Example of Released sticker

Released Material Area

Materials must be transferred from the Inspection holding area to the Released storage area after passing inspection.

Shelves for Released material should be in a separate location for storage and marked properly.

Material status boards should be posted to the front end of the shelf with material information & location. Release and FIFO stickers on each item should face the aisle.

Released Material Area Materials must be transferred from the Inspection holding area to the Released storage
F F
F
F

Incoming Material Area

The Color Blue Area Location ID Sign indicates this area is for Incoming Materials and Inspection

Incoming Material Area The Color Blue Area Location ID Sign indicates this area is for Incoming
Incoming Material Area The Color Blue Area Location ID Sign indicates this area is for Incoming

April 2014

Example of Temporary Released/ Rejected Holding Areas

Example of Temporary Released / Rejected Holding Areas In the Incoming Inspection Warehouse, Temporary Holding Areas

In the Incoming Inspection Warehouse, Temporary Holding Areas for Released/ Rejected material must be clearly identified with correct color signs (Green for Released and Red for Rejected).

Note that the color Brown is used for painted

lines on the floor

Example of Temporary Released / Rejected Holding Areas In the Incoming Inspection Warehouse, Temporary Holding Areas

Material Preparation Area

The Material Preparation area is a separate area, where Released materials are prepared for issuance to production. The PREPARATION area is identified with a Yellow color area ID sign.

Material Preparation Area The Material Preparation area – is a separate area, where Released materials are
Material Preparation Area The Material Preparation area – is a separate area, where Released materials are

Incoming Material Warehouse

Rejected Material Areas Rejected materials are those which do not pass either the visual inspection or the physical inspection. Rejected materials should be claimed back to suppliers in accordance with the respective country specific policy.

The Rejected Material Area should be secured with a lock to avoid mixing with all other materials and an A4 size information sheet with a color photo, name and contact number of the person who controls the key must be posted near the lock.

Incoming Material Warehouse Rejected Material Areas Rejected materials are those which do not pass either the

NOTE: The key must be kept by a QMS team member

Incoming Material Warehouse Rejected Material Areas Rejected materials are those which do not pass either the

22

Table to be posted on the wall

Matrix for Visual Inspection of Incoming Material

16 - 25 200 10.001 - 36.000 91 - 150 Incoming Lot Accepted / Released AQC
16 - 25 200 10.001 - 36.000 91 - 150 Incoming Lot Accepted / Released AQC
16 - 25
200
10.001 - 36.000
91 - 150
Incoming Lot
Accepted / Released
AQC Score
0 - 8
2
.9 - 15
3
3001 - 10.000
5
26 - 50
13
51 - 90
8
20
Sample Number
n
2000
315
36.001 - 70.000
600
70.001 - 120.000
12.001 - 170.000
1250
170.001 - 250.000
( over 250.000 include material )
1000
80
151 - 200
32
2001 - 500
50
5001 - 1200
1201 - 3000
126
1 2,5 AC AC Re Re 0 0 1 1 0 0 1 1 0 0
1
2,5
AC
AC
Re
Re
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
2
0
1
1
2
1
2
2
2
1
3
2
4
3
6
3
6
3
7
4
9
4
10
6
11
7
14
8
15
10
21
11
22
14
21
15
22
21
21
22
22
21
21
22
22
AC
0
0
0
1
0
Re
4
22
21
21
21
21
2
3
5
7
10
14
22
22
22
21
22
15
11
8
6
4
3
2
2
1
1
1

General Level Inspection

Normal Inspection

Level Of Inspection

Inspection Method

NOTE :

1 . In program of materials inspection of parts of to be check visually as according to " visual Form Inspection of Incamoing material " : Hardness, Thickness ,Color

Appearance.Level inspection from material arrival differe can be altered by pursuant to former inspection wxperience.Classification assessment from supplier or

over all of material type will give an indocation to handle the inspection random by more flexible .

Table to be posted on the wall Matrix for Visual Inspection of Incoming Material 16 -

2. Material which Rejected have to re-inspect by increase up 1 level,if level 1 have been used ,do by 100% inspection.if material 2 time do by 100% inspection.

Incoming Materials Inspection

Accessories are inspected:

  • a. By Piece Shoe laces, transfer paper, size labels, TR Counters, D-rings, heel plugs,

Booklets, Hang Tags, Eyelets

  • b. In Rolls/meters Thread, Velcro, Webbing, Elastic Gore

  • c. In Sheets Outer Carton boxes, Inner boxes

Incoming Material QC Workstations

Incoming Material QC Workstations Each QC should have clear workstation And clear visual colored area to

Each QC should have clear workstation And clear visual colored area to place:

Green : released material

Blue

: waiting inspection

Red

: rejected

Visual Inspection of Leather

For checking:

  • - Material appearance: Refer to Confirmed Shoes (PCS), Spec sheet/OIB

  • - Color: Refer to Swatch and or PCS

  • - Thickness: Use gauges

  • - Hardness: Use hardness gauge

  • - Dimensions: Use ruler, tape and/or caliper

Note: If material FAILs visual inspection it does not need to be sent to the lab for physical testing.

Visual Inspection of Leather For checking: - Material appearance : Refer to Confirmed Shoes (PCS), Spec
Visual Inspection of Leather For checking: - Material appearance : Refer to Confirmed Shoes (PCS), Spec

Examples of tools Incoming Inspection QC’s must have on hand for proper inspection of Leather:

  • 1. Measuring devices

Examples of tools Incoming Inspection QC’s must have on hand for proper inspection of Leather :
  • 2. Material swatch books

Examples of tools Incoming Inspection QC’s must have on hand for proper inspection of Leather :

3. PCS in place and used during inspection

Examples of tools Incoming Inspection QC’s must have on hand for proper inspection of Leather :
Examples of tools Incoming Inspection QC’s must have on hand for proper inspection of Leather :

27

Incoming Leather Materials

Each factory should prepare a Leather Defect catalogue to be used during Inspection

Examples of Items to Include in DEFECT CATALOGUE

SCRATCHES
SCRATCHES
BACKING HAIRY
BACKING HAIRY
LOOSE GRAIN
LOOSE GRAIN
BRAND MARKS
BRAND MARKS
GROWTH MARKS
GROWTH MARKS
TICK MARKS
TICK MARKS

4.4 eIncoming Materials Lab Testing

Method and Tools

Physical/Lab - Testing

  • - All Incoming materials must pass physical lab tests before being Release.

  • - Test frequency for each type and batch of material is established by the NB Lab Manager.

  • - Physical testing for production materials must be conducted according to NB standards.

  • - Specimens should be taken only by authorized QMS QC personnel.

Table to be posted on the wall

 

STANDARD TABLE OF RANDOM SAMPLING PHYSICAL TEST

NO

MATERIAL NAME

 

RECEIVED

RANDOM SAMPLING QUANTITY

REMARK

QUANTITY

FOR PHYSICAL TEST

 

LEATHER

0

- 20.000 sf

  • 1 Piece

 

1

20.001

- 40.000 sf

  • 2 Piece

 

40.001

- 60.000 sf

  • 3 Piece

 

60.001

- ….

  • 4 Piece

 
 

OUTSOLE/MIDSOLE

0

- 5.000 prs

  • 1 Pairs

 

INLAYSOLE

5.001

- 10.000 prs

  • 2 Pairs

 

2

10.001

- 20.000 prs

  • 3 Pairs

 

20.001

- ….

  • 4 Pairs

 
 

TEXTILE,PVC, SYNTHETIC

0

- 50 Rolls

  • 1 Roll / Type

 

3

51

- 100 Rolls

  • 2 Roll / type

 

101

- 150 Rolls

  • 3 Roll / Type

 

151

- ….

  • 4 roll ? Type

 
 

ACCESSORIES

Material type " A "

  • 1 Specimen for once physical Test

 

0

- 25 Cartons

  • 1 Specimen for once physical Test

 

26

- 50 cartons

  • 1 Specimen for once physical Test

 

51

- … ..

   

Material Type " B "

   

4

0

- 100 Rolls

  • 1 Specimen for once physical Test

 

101

- 200 Rolls

  • 1 Specimen for once physical Test

 

201

-

….

  • 1 Specimen for once physical Test

 

Material Type

" C "

   

0

- 10.000 pcs

  • 1 Specimen for once physical Test

 

1.0001

- 20.000 pcs

  • 1 Specimen for once physical Test

 

20.001

- ....

  • 1 Specimen for once physical Test

 
 

Remark

: Material Type "A" = Carton Box and Inner Boxes

 

Material Type "B" = thread, webbing tape, Velcro, Plastic band

 

Material Type "C" + TR Counter, Torsion Bar,TPR Logo,Button,eyelet,Shoe

Lace,Tongue,Label,Hang Tag,Size

 

Label,Sticker,Booklet,Transfer Label

 
 
2.2 Implementation On the Line (Quality Control in Production)
2.2
Implementation On the Line
(Quality Control in Production)

Implementation on the Line

Product supervisors are responsible for controlling process and product

quality during Implementation on the Line. However, quality control is enhance

by adding QC Inspectors, Roving Inspectors (RQC) and End-of-Line QC inspectors (EOL QC).

Generally:

  • 1 QC Inspector at the end of each upper stitching line;

  • 1 or 2 EOL QC at the end of each production line; and,

  • 1 RQC to cover no more than two production lines

Roving & EOL QC Identification

Colored hats must be worn by both the QMS Roving (RQC) and the EOL QC.

Other QC personnel my have colored shirts or hats to identify them as well:

  • A. RQC or Roving = Orange color hats with Black letters

    • B. EOL QC = Red color hats with Yellow letters

    • C. Incoming W/H, Rubber Room and Stitching QC’s also = Red color hats with Yellow letters

Roving & EOL QC Identification Colored hats must be worn by both the QMS Roving (RQC)
Roving & EOL QC Identification Colored hats must be worn by both the QMS Roving (RQC)
End-of-Line QC (EOL QC)
End-of-Line QC
(EOL QC)

Responsibilities for EOL QC

EOL QC’s are placed at the end of each production line to

conduct visual inspection of 100% of the product that flows

from that line.

Responsibilities for EOL QC EOL QC’s are placed at the end of each production line to
EOL QC EOL QC’s must have sufficient work space and good lighting to conduct proper inspection

EOL QC

EOL QC EOL QC’s must have sufficient work space and good lighting to conduct proper inspection
EOL QC EOL QC’s must have sufficient work space and good lighting to conduct proper inspection

EOL QC’s must have sufficient work space and good lighting to conduct proper inspection of the product.

All required tools and materials below should be available:

  • a. QC Red arrow stickers

  • b. Daily Quality Report

  • c. Pen to record defects on the Daily Quality Report

  • d. Clip board to hold Daily Quality Report

  • e. 6 inch steel ruler

  • f. Inspection tooling gauge to measure stitch length

  • g. B- Grade stamp

  • h. PCS update per 3 months

EOL QC EOL QC’s must have sufficient work space and good lighting to conduct proper inspection
EOL QC EOL QC’s must have sufficient work space and good lighting to conduct proper inspection

36

Two (2) Defect Carts on wheels should be available for the EOL QC to place defective shoes

The Defect Carts should have 3-4 shelves labelled Dirty - Assembly - Stitching & Cutting. When 1 Cart is full the EOL QC turns the shoes over to the production line supervisor and then takes the 2 nd Cart back to the work station. The Line supervisor takes the Defect Cart to each applicable location and returns the shoes to the appropriate operators to be repaired. The operators repair the defects (when possible) and place the shoes back on the line.

Good lighting

The EOL QC also needs proper lighting to be able to see and identify defects clearly

Two (2) Defect Carts on wheels should be available for the EOL QC to place defective

An EOL QC’s Workstation

Two (2) Defect Carts on wheels should be available for the EOL QC to place defective

Defects Cart

EOL QC Work station

The EOL QC Work station for EOL QC must be clearly Identified with a large sign Above the work station (Yellow background with Red lettering).

EOL QC Work station The EOL QC Work station for EOL QC must be clearly Identified
EOL QC Work station The EOL QC Work station for EOL QC must be clearly Identified

The EOL QC must consistently identify defect locations on product using defect arrow stickers and must record each defect on a Daily Quality Report .

EOL QC Work station The EOL QC Work station for EOL QC must be clearly Identified
EOL QC Work station The EOL QC Work station for EOL QC must be clearly Identified

.

5.2 Tollgate Quality Control (TQC) after assembly and stitching

B-Grades at EOL QC

areas

Certified EOL QC’s are empowered to B-grade product when necessary. For this purpose a lockable Red colored box must be placed at each EOL QC work station to temporarily secure B- Grade shoes until the end of the day:

. 5.2 Tollgate Quality Control (TQC) after assembly and stitching B-Grades at EOL QC areas Certified

NOTE:

EOL QC’s must be empowered to make decision to B-Grade shoes and stop the line

5.2 Tollgate Quality Control EOL

Repairs at EOL QC

No repair is allowed by EOL QC’s.

5.2 Tollgate Quality Control EOL Repairs at EOL QC No repair is allowed by EOL QC’s

5.2 Tollgate Quality Control EOL

Metal Detection at EOL QC

Metal detectors must be used to detect any contamination of metal such as, broken needle fragments or metal filings in materials or stuffing paper.

All shoes are passes through the Metal Detector after the EOL QC check.

  • a. If the MD alarm sounds or flashes as the shoes pass through the shoes are isolated

  • b. The RQC and Line Supervisor will use handheld MD to determine if metal is detected in L or R shoe

  • c. If metal detected, shoe is cut to locate metal object and report

5.2 Tollgate Quality Control EOL Metal Detection at EOL QC Metal detectors must be used to
5.2 Tollgate Quality Control EOL Metal Detection at EOL QC Metal detectors must be used to
5.2 Tollgate Quality Control EOL Metal Detection at EOL QC Metal detectors must be used to
MD‘s are Calibrated by RQC Twice Daily ALERT STEP 1 CENTER LEFT RIGHT MD’s alarm should
MD‘s are Calibrated by RQC Twice Daily
ALERT
STEP 1
CENTER
LEFT
RIGHT
MD’s alarm should sound
and the machine
should stop.
Put Ferrous test-tick in the center then left
and right side and pass through the conveyor belt
Ferrous ball test
stick diameter
1.5 mm
MD‘s are Calibrated by RQC Twice Daily ALERT STEP 1 CENTER LEFT RIGHT MD’s alarm should
CENTER STEP 2
CENTER
STEP 2

Put the Ferrous test- tick on top of a 50 mm High box in the center ans

pass through the

conveyor belt

ALERT
ALERT
CENTER STEP 2 Put the Ferrous test- tick on top of a 50 mm High box
MD’s alarm should sound and the machine should stop.
MD’s alarm should
sound and the
machine
should stop.
CENTER STEP 2 Put the Ferrous test- tick on top of a 50 mm High box
MD‘s are Calibrated by RQC Twice Daily ALERT STEP 1 CENTER LEFT RIGHT MD’s alarm should
MD‘s are Calibrated by RQC Twice Daily ALERT STEP 1 CENTER LEFT RIGHT MD’s alarm should
MD‘s are Calibrated by RQC Twice Daily ALERT STEP 1 CENTER LEFT RIGHT MD’s alarm should
diameter 2 mm MIDDLE STEP 3 Put Non Ferrous test- conveyor belt tick in the center
diameter 2 mm
MIDDLE
STEP 3
Put Non Ferrous test-
conveyor belt
tick in the center and
pass through the
Non Ferrous
ball test-tick
STITCHING QC
STITCHING QC

Stitching QC Check Points for Inspection of Stitched Uppers

Check top view of Uppers (eyestay & eyelet alignment , logos & toe centered)

Check top view of Uppers

(eyestay & eyelet alignment , logos & toe centered)

1
1
2
2
2 Check Heel area (Logo, heel patch and back tab must be centered)

Check Heel area

(Logo, heel patch and back tab must be centered)

3
3

Check inside of uppers

(lining stitched around toe , no

thread ends or excess cement )

4
4
4 5
5
5
4 5

Check tongue

Check size labels

(Stitched in straight, collar lining even,

Centred and consistent

 

All folding must be flat)

 

Examples of common issues Stitching QC’s look for

Examples of common issues Stitching QC’s look for Loose thread ends Logo wrinkles Inconsistent alignment of

Loose thread ends

Examples of common issues Stitching QC’s look for Loose thread ends Logo wrinkles Inconsistent alignment of

Logo wrinkles

Examples of common issues Stitching QC’s look for Loose thread ends Logo wrinkles Inconsistent alignment of
Examples of common issues Stitching QC’s look for Loose thread ends Logo wrinkles Inconsistent alignment of

Inconsistent alignment of webbing

Misaligned notches and Stains or cement on uppers

Examples of common issues Stitching QC’s look for Loose thread ends Logo wrinkles Inconsistent alignment of

Inconsistent Stitching margin

Examples of common issues Stitching QC’s look for Loose thread ends Logo wrinkles Inconsistent alignment of

Stitching open

Examples of common issues Stitching QC’s look for

Examples of common issues Stitching QC’s look for Vamp/toe shape off center Misalignment Damage punched holes

Vamp/toe shape off center

Examples of common issues Stitching QC’s look for Vamp/toe shape off center Misalignment Damage punched holes
Examples of common issues Stitching QC’s look for Vamp/toe shape off center Misalignment Damage punched holes

Misalignment

Damage punched holes

Examples of common issues Stitching QC’s look for Vamp/toe shape off center Misalignment Damage punched holes

Upper wrinkles

Examples of common issues Stitching QC’s look for Vamp/toe shape off center Misalignment Damage punched holes

Visible gauge marks

Examples of common issues Stitching QC’s look for Vamp/toe shape off center Misalignment Damage punched holes

Misaligned or excess Reinforcement

ROVING QC (RQC)
ROVING QC
(RQC)

Responsibilities for RQC

RQC’s monitor and control process and product quality from

cut to box . An RQC should only be responsible for maximum of two (2) production lines.

Responsibilities for RQC RQC’s monitor and control process and product quality from cut – to –
Responsibilities for RQC RQC’s monitor and control process and product quality from cut – to –

RQC

Checklist

RQC’s Duties

Ensure that a correct SOP is clearly displayed (in color) at each operator work station

1 2 3 SOP Check Points:
1
2
3
SOP Check Points:
  • 1. Clearly explains the SOP for the specific process in production

  • 2. SOP shows critical areas to check.

  • 3. SOP has correct reference number

Roving QC (RQC)

Example RQC Checklist

Roving QC (RQC) Example RQC Checklist RQC’s must carry their work instruction and Daily Checklist with

RQC’s must carry their work instruction and Daily Checklist with them on a clip board. NOTE: RQC’s are monitoring production lines to control quality consistency. They should be well trained in production processes and NB quality standards and demonstrate good

self-confidence and decision making ability.

RQC’s monitor machine settings and operating times, temperatures, pressure

and work closely with production supervisors to ensure any issues are

addressed and resolved quickly.

RQC’s monitor machine settings and operating times, temperatures, pressure and work closely with production supervisors to
RQC’s monitor machine settings and operating times, temperatures, pressure and work closely with production supervisors to
RQC’s monitor machine settings and operating times, temperatures, pressure and work closely with production supervisors to
RQC’s monitor machine settings and operating times, temperatures, pressure and work closely with production supervisors to

51

RQC’s Check Cutting Boards

Cutting Boards need to be color coded on two opposite end corners to facilitate control

- Every 4 hours the cutting board should be turned 180° (showing a different color) - Every 8 hours the cutting board should be flipped over to ensure optimal use of cutting surface

Painted colors on corners
Painted colors on corners
x
x

Note : Cutting board should be in good condition to ensure

smooth edge cutting

RQC’s Check Cutting Boards Cutting Boards need to be color coded on two opposite end corners

RQC’s Check Cut Components

Control of Cut Components

Cut Components are generally placed in plastic baskets to maintain control by size and quantity and to keep them clean.

-Baskets should be clean and the -Component size and quantity should -be marked on the end of the basket

RQC’s Check Cut Components Control of Cut Components Cut Components are generally placed in plastic baskets
x
x

Note : Component Quality and Quantities must be controlled

Examples of common issues RQC’s look for at Cutting

Examples of common issues RQC’s look for at Cutting Poor Perforation holes Cutting dies not matching

Poor Perforation holes

Examples of common issues RQC’s look for at Cutting Poor Perforation holes Cutting dies not matching

Cutting dies not matching pattern

Hairy edges of cut components

Examples of common issues RQC’s look for at Cutting Poor Perforation holes Cutting dies not matching

Creases in layered materials

Examples of common issues RQC’s look for at Cutting Poor Perforation holes Cutting dies not matching

Damaged components

RQC’s Check Cutting Dies

Control Cutting dies

  • - Cutting dies must be flat

  • - Cutting dies must be sharp

  • - Cutting dies should not become rusty

  • - Cutting dies are placed in EVA material cut-out

  • - to prevent cutting knife edge damage

x
x

Note : Cutting dies should not become rusty

RQC’s Check Cutting Dies Control Cutting dies - Cutting dies must be flat - Cutting dies

Cutting Die

RQC’s Cutting Die Check

Cutting Die RQC’s Cutting Die Check Pattern Operator check if deform before operation 100% flat glass

Pattern

Cutting Die RQC’s Cutting Die Check Pattern Operator check if deform before operation 100% flat glass

Operator check if deform before operation

Cutting Die RQC’s Cutting Die Check Pattern Operator check if deform before operation 100% flat glass

100% flat glass

Cutting Die RQC’s Cutting Die Check Pattern Operator check if deform before operation 100% flat glass

Check if surface flat

RQC’s should check that pattern construction is correct

RQC’s should check that pattern construction is correct

RQC’s check that Zig-Zag stitching is correct

Width stitching 5 -6 mm

Left and Right components height must be flat L Component R Component Component must be flat
Left and Right
components height must
be flat
L Component
R Component
Component must be flat
Not overlap
Locked stitch 3 – 4 stitches
size code
a b c
Range right stitch and left
must the same (ab = bc)

RQC’s should monitor Daily Broken Needle Reports

The issue of needles to the operators is controlled by the Stitching Supervisor. When an operator has a broken needle they must immediately call their

Supervisor and the RQC to report and locate all broken needle pieces.

After locating all broken pieces of the needle, they are taped onto a Daily Broken Needle Report and the Date, Cell # and PO are recorded. The supervisor may then issue a new needle to the operator.

RQC’s should monitor Daily Broken Needle Reports The issue of needles to the operators is controlled
RQC’s should monitor Daily Broken Needle Reports The issue of needles to the operators is controlled

Needles are

All broken pieces must be found before

controlled by

new needle can be issued to operator

Supervisor

RQC’s Duties include checking Processes

RQC checks that Critical processes are being done correctly:

Strobel stitching to attach the Strobel board to the upper.

Strobel stitching should be closed all the way around and flat.

Back part molding

Times and Temperatures

must be checked

RQC’s Duties include checking Processes RQC checks that Critical processes are being done correctly: Strobel stitching
RQC’s Duties include checking Processes RQC checks that Critical processes are being done correctly: Strobel stitching

RQC’s Duties include checking Processes

Lasting Process

RQC’s Duties include checking Processes Lasting Process Hand Buffing Process Buffing the surface of leather to
RQC’s Duties include checking Processes Lasting Process Hand Buffing Process Buffing the surface of leather to

Hand Buffing Process

Buffing the surface of leather to create a strong bond

RQC’s Duties include checking Processes Lasting Process Hand Buffing Process Buffing the surface of leather to
RQC’s Duties include checking Processes Lasting Process Hand Buffing Process Buffing the surface of leather to

RQC’s Duties include checking Processes

RQC checks that Critical processes are being done correctly:

Priming, Cementing Process

Primer and cementing

must be even.

Attaching Process

The function is to attach the upper and bottom unit following the parking and buffing process

RQC’s Duties include checking Processes RQC checks that Critical processes are being done correctly: Priming, Cementing
RQC’s Duties include checking Processes RQC checks that Critical processes are being done correctly: Priming, Cementing
RQC’s Duties include checking Processes RQC checks that Critical processes are being done correctly: Priming, Cementing

RQC’s Duties include checking Processes

Pressing Process

The function is pressing the upper and outsole together

to ensure a solid bond.

RQC’s Duties include checking Processes Pressing Process The function is pressing the upper and outsole together
  • 1. Ensure the pressing pad size is correct

  • 2. General pressing standard is 30 kg/ cm for 10 seconds.

Insert & Components

All components for use in

production i.e. Inserts, Strobel boards, heel counters

etc., must be clearly separated and marked by size

for clear visual identification

RQC’s Duties include checking Processes Pressing Process The function is pressing the upper and outsole together
RQC’s Duties include checking Processes Pressing Process The function is pressing the upper and outsole together
RQC’s Duties include checking Processes Pressing Process The function is pressing the upper and outsole together

Note : Toe stuffing paper should be inserted after EOL QC

Examples of common issues RQC’s look for

Examples of common issues RQC’s look for Poor Alignment Loose/open Strobel Bonding Wrinkled Midsole Over cementing

Poor Alignment

Examples of common issues RQC’s look for Poor Alignment Loose/open Strobel Bonding Wrinkled Midsole Over cementing
Examples of common issues RQC’s look for Poor Alignment Loose/open Strobel Bonding Wrinkled Midsole Over cementing

Loose/open Strobel

Bonding

Examples of common issues RQC’s look for Poor Alignment Loose/open Strobel Bonding Wrinkled Midsole Over cementing

Off center heel

Examples of common issues RQC’s look for Poor Alignment Loose/open Strobel Bonding Wrinkled Midsole Over cementing

Wrinkled Midsole

Examples of common issues RQC’s look for Poor Alignment Loose/open Strobel Bonding Wrinkled Midsole Over cementing

Over cementing

* All the defects refer to NB Defects classification

Examples of common issues RQC’s look for

Examples of common issues RQC’s look for Inconsistent Toe spring Lining not caught by Strobel Variation
Examples of common issues RQC’s look for Inconsistent Toe spring Lining not caught by Strobel Variation
Examples of common issues RQC’s look for Inconsistent Toe spring Lining not caught by Strobel Variation

Inconsistent Toe spring

Lining not caught by Strobel

Variation in

stitching

Heel Heights

RQC’s Monitor Chemical Color Codes

Examples of required bowl covers with colored stickers to identify primer or cement and solvent or water based as well as the shelf life times the chemical may be used i.e.,

11:00 12:00 or 15:00 16:00 for example.

Visual color coding for chemical Bowls and Brushes

RQC’s Monitor Chemical Color Codes Examples of required bowl covers with colored stickers to identify primer
RQC’s Monitor Chemical Color Codes Examples of required bowl covers with colored stickers to identify primer
RQC’s Monitor Chemical Color Codes Examples of required bowl covers with colored stickers to identify primer

Application Brushes are color coded and should follow the same color as the bowl cover i.e., a BLUE bowl cover requires that the Operator also be using a BLUE colored brush. The change times should be clearly posted at the workstation

RQC’s Monitor cleanliness and serviceability of shoe Lasts

RQC’s Monitor cleanliness and serviceability of shoe Lasts Lasts should be cleaned and stored properly by

Lasts should be cleaned and stored properly by sixe after each use

x
x
x
x
x
x

Note : Lasts must be clean and not damaged or rusted

RQC’s Monitor Serviceability of Production Confirmation Samples (PCS)

Confirmation Sample Handling:

  • RQC’s should monitor the PCS’s to ensure they are clean and serviceable

  • All PCS should have signed hangtag attached showing last date reviewed

  • All PCS should be kept in Zip-lock plastic bags to keep them clean

  • If a PCS needs to be replaced, a half pair is taken from production and must be signed by both the factory QMS Manager & the NB QA

RQC’s Monitor Serviceability of Production Confirmation Samples (PCS) Confirmation Sample Handling :  RQC’s should monitor
2.3 Finish Goods Warehouse Visual Color Management Location & Status Board SI Room Status Board Row
2.3 Finish Goods Warehouse
Visual Color Management
Location & Status Board
SI Room Status Board
Row Separation
Stack Heights
Process Flow
Layout (Example)

69

Visual Color Management

Visual color codes in the Finished Goods W/H are designed :

  • 1. To connect production, F/G warehouse , SI areas and

shipping for end to end monitoring .

  • 2. To establish a tracking system to easily locate PO’s and quickly identify the status of each PO.

  • 3. To eliminate search time in locating F/G’s in the warehouse.

  • 4. To implement a user friendly organized environment without continual shifting of PO location

  • 5. To standardize the F/G process flow for easy monitoring and control.

Location Status Board

F/G Warehouse PO location & status board color code identification

a. Color codes for PO status in F/G Warehouse:

F/G warehouse status boards with magnets is preferred:

Yellow = for PO’s not yet complete Blue = for PO’s completed and awaiting inspection Green = for PO’s which have been inspected and released (ready for shipment). Red = for PO’s inspected and rejected Black = PO cannot pass through outer carton MD because of metal shoe part.

Location Status Board F/G Warehouse PO location & status board color code identification a. Color codes

SI Room Status Board

Shipping Inspection Room Status Board Color Codes

b. Color code for SI Room PO status board for daily inspections

Blue magnet = for PO’s awaiting SI Green magnet = for PO SI complete and released Red magnet = for Rejected PO’s

SI Room Status Board Shipping Inspection Room Status Board Color Codes b. Color code for SI

Shipping Inspection holding area color codes

c. Colors code for SI holding area borders Colors for border lines or stand-up signs in holding area outside SI room:

Blue = PO’s awaiting inspection Green = PO’s already inspected and released Red = PO’s Rejected

Shipping Inspection holding area color codes c. Colors code for SI holding area borders Colors for
Shipping Inspection holding area color codes c. Colors code for SI holding area borders Colors for
Shipping Inspection holding area color codes c. Colors code for SI holding area borders Colors for

Warehouse Row Border Lines

Color codes identification for Border Lines in the F/G W/H

Row border line colors (painted on the floor )

  • For Scan & Pack area = White Border Lines

  • For all other PO’s = Lines may be any color except RED, BLUE, or GREEN

  • Row number should be painted on floor at the front of each row

This factory is using orange color for Warehouse row boarders

Warehouse Row Border Lines Color codes identification for Border Lines in the F/G W/H Row border

74

Color Code Identification Magnets

  • e. Colored magnets are preferred to attach to Row Placards to identify PO status

Yellow Magnet = PO not yet complete Blue Magnet = PO complete and awaiting inspection . Green Magnet = PO inspected and released, ready for shipment. Red Magnet = PO rejected and awaiting re-inspection or other disposition. Black Magnet = PO cannot pass through outer carton MD because of metal shoe part.

Use of Magnets makes it easy to update PO status throughout the process.

Color Code Identification Magnets e. Colored magnets are preferred to attach to Row Placards to identify
Color Code Identification Magnets e. Colored magnets are preferred to attach to Row Placards to identify
Color Code Identification Magnets e. Colored magnets are preferred to attach to Row Placards to identify
Color Code Identification Magnets e. Colored magnets are preferred to attach to Row Placards to identify

Recommended Warehouse Row Separation Distance

+ - 1 meter
+ - 1 meter

Carton Stacking Heights

The purpose of limiting carton stack heights is to prevent crushing or damaging cartons from stacks that are too high or too heavy.

The recommend stack heights are :

  • M’s/W’s ( size ) = 6 cartons high

  • Junior / Kid’s ( size ) = 7 cartons high

Note: Factories need to use best judgment for heavier/larger cartons (4 or 5 high)

Carton Stacking Heights The purpose of limiting carton stack heights is to prevent crushing or damaging
6 cartons high
6 cartons high
Carton Stacking Heights The purpose of limiting carton stack heights is to prevent crushing or damaging
7 cartons high
7 cartons high
END
END